Flexible automotive assembly workstation and method

ABSTRACT

An apparatus for assembling multiple automotive body styles on a single assembly line. The apparatus includes a workstation with multiple geometry fixtures, at least one geometry fixture for each automotive body style to be processed at the work station. One geometry fixture is at a ready position of the work station to support an automotive component during a processing operation. The geometry fixtures can be exchanged at the ready position so that a production rate of the assembly line can be maintained. The apparatus also includes a lowerator for transferring an automotive component from an overhead transport system to the geometry fixture at the ready position.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. Provisional PatentApplication Serial No. 60/180,607, filed Feb. 7, 2000. This applicationis filed contemporaneously with two other applications, “FLEXIBLEAUTOMOTIVE ASSEMBLY LINE AND METHOD” our attorney's reference no.PTC-256-B, and “INTERCHANGEABLE NESTS FOR SUPPORTING COMPONENTS ON ATRANSPORT SYSTEM” our attorney's reference no. PTC-257-A.

FIELD OF THE INVENTION

[0002] The present invention relates to a method and apparatus for theflexible assembly of a plurality of automotive body styles on a singleassembly line with zero loss of production during changeover.

BACKGROUND OF THE INVENTION

[0003] Current body assembly lines typically use a palletized approachfor assembling components of the automotive body style to be built andfor joining those components to one another at a framing station. Thepalletized approach requires that sufficient pallets be provided foreach type of body style to be assembled and transported along theassembly line at one time, including spares for any pallets that may bedamaged during the assembly process. When this number is multiplied bythe number of models to be produced on the assembly line, the number ofpallets can be a very large number requiring large amounts of off linestorage space and also requiring a tremendous amount of maintenance tomaintain the accurate geometry required of a palletized fixture.

SUMMARY OF THE INVENTION

[0004] It would be desirable to reduce the number of pallets requiredfor a modern automotive assembly line capable of producing a pluralityof automotive body styles on the same line without any loss ofproduction during changeover. It would be desirable in the presentinvention to provide an assembly line configuration capable of buildinga single automotive body style, two automotive body styles, threeautomotive body styles, or four automotive body styles without loss ofproduction, and without requiring excessive changes in the productionline configuration. It would be desirable in the present invention toprovide an overhead component delivery system for the early stages ofthe assembly line, while providing a palletized transportation systembetween the workstation beginning at the underbody respot station. Itwould be desirable to provide an overhead transport system for thecomponent assembly line which is capable of quick and efficientchangeover of body style fixtures to produce different body styleswithout interruption of production. It would be desirable to provide aflexible assembly workstation having an interchangeable workpiecesupport or geometry fixture for the different body styles to bemanufactured through the workstation, where the different supportfixtures can be interchanged with one another without loss ofproduction.

[0005] A flexible automotive body assembly line according to the presentinvention includes an overhead component transport system. The overheadtransport system preferably is provided for the bodyside left handassembly line, bodyside right hand assembly line, and underbody assemblyline and tack workstation. After the underbody is tacked at theunderbody tack workstation, the underbody is transported by an overheadtransport system and transferred to a palletized system at the underbodyrespot workstation. After respot, the pallet system transfers theunderbody to the framing workstation, where the bodyside left and righthand components are delivered by the overhead system. The framingworkstation positions the left hand and right hand components of thebodysides to the underbody and tacks the right and left components withrespect to the underbody. The pallet then transfers the assembledworkpiece to the roof framing fixture and continues through the framingrespot workstation where additional welding and tacking is performed.The pallet system then transfers the assembled framed body to closureworkstations where closure panels can be assembled prior to deliveringthe assembled body to the paint station.

[0006] Preferably, the overhead delivery system for the bodyside lefthand assembly line, the bodyside right hand assembly line, and theunderbody tack workstation is an electric monorail system. The electricmonorail system can provide an overhead rail extending between thevarious workstations, and preferably extends in a circular or loopconfiguration passing through the workstations and through a workpiecesupport or antler exchange workstation for preparing the overheaddelivery system to receive and transport different body styles or modelsthrough the assembly line without any loss of production. The electricmonorail system can include a carriage powered by an electric motor formovement between the workstations along the overhead monorail.

[0007] Downwardly extending supports or pillars extend from the carriagefor receiving the workpiece support or antlers there between. Theworkpiece supports or antlers are interchangeable as required forengaging the particular body style or model of components to bemanufactured through the assembly line. The vertically extendingsupports or pillars include a telescoping function to allow theworkpiece support or antlers to be moved from a vertically raisedposition used to transport the workpiece or components betweenworkstations, and a vertically lowered position at a workstation todeliver the workpiece or a component to the workpiece support, nest orgeometry fixture at the particular workstation. The vertically extendingsupports or pillars also include latching mechanisms to hold theworkpiece support or antlers in the raised position during transportbetween workstations. Preferably, the drive for unlatching and loweringthe workpiece support or antlers and supported workpiece or component isprovided at each workstation, and includes a single drive for eachvertically extending support or pillar of the electric monorail carriagesystem. Preferably, the single drive for each vertically extendingsupport or pillar of the carriage located at the workstation is capableof unlatching the latch mechanism prior to lowering the workpiecesupport or antlers at the workstation location, and after the work hasbeen performed at that workstation raising the work support or antlerportion of the carriage to the raised position and latching the latchmechanism of the vertically extending support or pillars from thecarriage prior to the carriage leaving the workstation.

[0008] The present invention also includes a flexible body assemblyworkstation. For purposes of illustration, a single workstation will bedescribed. The flexible body assembly workstation can be used at thebodyside left hand assembly location, the bodyside right hand assemblylocation, the underbody tack assembly workstation, or any other majorsubassembly component. The workstation preferably includes an overheadcomponent delivery system extending through the workstation. Theoverhead delivery system can enter the workstation empty, or can delivera partially completed component to the workstation for additionalassembly steps. In either case, a workpiece support or geometry fixtureis provided at the flexible body assembly workstation for receiving theparts to be built up into the component to be transported, or to beadded to the partially completed component delivered by the overheadsystem. The workpiece support or geometry fixture at each flexible bodyassembly workstation is interchangeable to match the body style or modelto be manufactured at the workstation for that particular operationcycle. Preferably, the flexible assembly workstation includes sufficientcapacity to handle up to four different workpiece support or geometryfixtures for use on demand at the workstation depending on theparticular body style or model to be manufactured at the workstation. Inone configuration, the workpiece supports or geometry fixtures areconnected to a delivery system capable of moving the fixtures betweenthe standby or storage positions and a ready position for receiving theworkpiece component to be delivered to the workstation. In thealternative, a workpiece support or geometry fixture can be deliveredusing an “H-Gate” configuration. The H-Gate delivery system uses alinear transfer system, such as a rail delivery to the workstation readyposition and between two standby or storage positions on either side ofthe station. The standby positions are serviced by two transverselyextending delivery systems. One delivery system is provided on each sideof the workstation producing the “H” configuration for which the systemis named. The transversely extending delivery systems provide, orpre-load, the next workstation support or geometry fixture required atthe workstation. For changeover, the current workpiece support orgeometry fixture and the new workpiece support or geometry fixture arereciprocated simultaneously along the rail system bringing the newworkstation support or geometry fixture into the workstation andremoving the previously used workpiece support or geometry fixture fromthe workstation. When properly located, the rail transfer system stopsin the appropriate position for the geometry fixture to be positioned atthe workstation. The old workpiece support or geometry fixture is thenremoved from the standby position by one of the transversely extendingdelivery systems. The process is then repeated by pre-positioning thenext desired geometry fixture at one of the standby positions forsubsequent delivery to the workstation on demand.

[0009] Other objects, advantages and applications of the presentinvention will become apparent to those skilled in the art when thefollowing description of the best mode contemplated for practicing theinvention is read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The description herein makes reference to the accompanyingdrawings wherein like reference numerals refer to like parts throughoutthe several views, and wherein:

[0011]FIG. 1 is a perspective view of the present invention, shown in anexemplary operational environment;

[0012]FIG. 2 is a lateral elevational view of the present invention,shown in an exemplary operational environment;

[0013]FIG. 3 is an end elevational view depicting the loweratormechanism of the present invention;

[0014]FIG. 4 is a detailed cross-sectional view of the latch means ofthe present invention;

[0015]FIG. 5 is a detailed perspective view of the latch means andlowerator mechanism of the present invention;

[0016] FIGS. 6A-6C provide detailed elevational views of the loweratormechanism in operation;

[0017]FIG. 7 is a side elevational view of the preferred embodiment of alowerator according to the present invention;

[0018]FIG. 8 is a detailed perspective view of the preferred embodimentof the lowerator according to the present invention;

[0019] FIGS. 9A-9C are detailed cross-sectional illustrations of thelatch mechanism and actuator of the preferred embodiment of thelowerator according to the present invention;

[0020]FIG. 10 is a simplified schematic diagram of a vertical positionsensor according to the present invention;

[0021]FIG. 11 is a simplified flow diagram of a control method for alowerator according to the present invention;

[0022]FIG. 12 is a simplified schematic illustrating the overheadtransfer system for component parts to the point where the underbody isput on a pallet system at the underbody respot workstation, and thebodyside preassemblies are attached to the underbody at the framingworkstation;

[0023]FIG. 13 is a perspective view of a lowerator for transporting theunderbody to and from the underbody tack workstation;

[0024] FIGS. 14A-14E are perspective views of various embodiments of anoverhead delivery system with interchangeable workpiece supports orantler configurations for different body styles or models;

[0025]FIG. 15 is a perspective view of an assembly line portion with anoverhead delivery system passing through a workpiece support or antlerexchange workstation, where the workpiece support or antlers can bechanged over to a new body style or model configuration duringproduction and a perspective view of an H-Gate delivery system for awork support or geometry fixture at a welding workstation;

[0026]FIG. 16 is a side elevational view of a workpiece support orantler or tray style selection apparatus for removing a previously usedworkpiece support or antler configuration and installing a new workpiecesupport or antler configuration for a new body style or model;

[0027]FIG. 16A is a perspective view of a robot for exchanging an antlernest with respect to a carrier;

[0028]FIG. 17 is a perspective view of loading stations, either manualor automated, positioned between two flexible body assemblyworkstations;

[0029]FIG. 18 is a perspective view of a load and/or unload automatedworkstation for the overhead delivery system between flexible bodyassembly workstations according to the present invention;

[0030]FIG. 19 is a perspective view of a flexible body assemblyworkstation according to the present invention having a plurality ofwelding robots positioned about the workstation, and overhead deliverysystem, and an interchangeable workpiece support or geometry fixture atthe workstation;

[0031]FIG. 20 is a plan view of the flexible body assembly workstationillustrated in FIG. 19;

[0032]FIG. 21 is a plan view of an “H-Gate” workpiece support orgeometry fixture configuration as an alternative for supplying theappropriate workpiece support to the flexible body assembly workstationas required for the particular body style or model to be manufactured;

[0033]FIG. 22 is a side elevational view of the H-Gate delivery systemillustrated in FIG. 21;

[0034]FIG. 23 is a simplified H-Gate cross section illustrating theoverhead delivery system and the H-Gate delivery system to the flexiblebody assembly workstation;

[0035] FIGS. 24A-24D illustrates alternative configurations for theH-Gate delivery system for the workpiece support or geometry fixturetooling to the flexible body assembly workstation according to thepresent invention allowing flexible set up between one model, twomodels, three models, and four models through the same flexible bodyassembly workstations; and

[0036]FIG. 25 is a perspective view of a palletized system for deliveryof the underbody to the respot workstation and on to the framingworkstation, framing respot workstation, closure workstation, and paintworkstation.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0037] Referring now to FIG. 1, the present invention generally includesworkpiece conveyance means 10 for transporting a workpiece along pathmeans 12 for defining a path of travel between workstations 14positioned along the path means, and locator means positioned at theworkstation and operative for locating the workpiece at the workstation.A lowerator 18 is provided for moving the workpiece between theconveyance means 10 and the locator means. For purposes of illustration,the lowerator 18 is shown in combination with an assembly systemincluding the path means 12 and workstations 14. The conveyance means 10transports workpieces between the workstations 14, where one or morespecific processing operations are performed on the workpieces. Forinstance, the assembly system can be in the form of an automotiveproduction line where workpieces, such as automotive body panels andframe components, are progressively assembled at the workstations 14along the path 12 of travel. While a particular operational environmentis illustrated herein, it is not intended to be limiting with respect tothe present invention, which will have numerous applications asunderstood by those of skill in the art.

[0038] More particularly, the path means 12 can include at least onerail 20, such as an overhead monorail, suspended from a supportstructure such as a coextensive horizontal spine 22 and intermittentlyspaced vertical supports 24. The workpiece conveyance means 10 includesdriving means in the form of a motor-driven trolley 26 operative to movethe conveyance means 10 along the rail 20 in known fashion. As withother aspects of the depicted operational environment, the illustrateddriving means are not intended to be limiting with respect to thepresent invention, and any desired driving means can be adopted to servethe purpose of moving the conveyance means 10 along the selected pathmeans 12 in the desired operational environment.

[0039] Referring now to FIGS. 2 and 3, the workpiece conveyance means 10generally includes both the trolley 26 and a carrier 28. The trolley 26is configured generally in an inverted “U” shape, with horizontal andvertical members. The horizontal member is fixed to a parallel-disposedsupport cross-piece providing a point of attachment for trolley 26 orother driving means as appropriate. The trolley 26 is thus immovablyassociated with the driving means and moves along the path means 12 inconjunction therewith. The carrier 28 is also generally in a “U” shape,including a horizontal member and a vertical member. Workpiece carryingmeans, such as carrier 28, in the form of a workpiece nest can include aplurality of projecting fingers or antlers disposed on a horizontalelement of the carrier 28 to support the workpiece being conveyed. Theconfiguration of the workpiece nest can take any form desired andappropriate for the workpiece to be conveyed and the work to beperformed thereon. Each of the trolley 26 and carrier 28 may includelengths of metal plates, beams, brackets, or tubing joined by welding,joining plates, or other known means, though other suitably strongmaterials can be substituted.

[0040] As indicated, the carrier 28 is slidingly associated with trolley26 so as to be moveable vertically in relation to the trolley 26 inorder to lower a workpiece into the workstation 14 without the necessityof lowering the entire conveyance means 10 and a section of the railmeans 20, as with some prior known mechanisms. Bearing blocks 30 areprovided, one associated with each of the vertical members, the bearingblocks being dimensioned to slidingly receive the vertical elements 34of the carrier 28 therein. Referring now to FIG. 4, bearing surfaces 32are provided along the length of vertical elements 34 to define a travelsurface for sliding movement of the carrier 28.

[0041] Means 36 are provided associated with the carrier 28 forreceiving the positioning means 38. Referring now to FIGS. 2 and 4,receiving means 36 can include a cam surface 40, such as a channel orslot, preferably provided at both ends of the horizontal member 42 ofthe carrier 28. Cam surface 40 is fashioned from metal or other suitablystrong material. The cam surface 40 illustrated in FIGS. 1-2 and 4-6Cincludes an outer travel surface extending beyond the channel opening todefine a radiused portion 44. The cam surface 40 is fixed between plates48 connected to the horizontal member 42 of the carrier 28. The plates48 include cut-out portions 50, leaving a sufficient length of each camsurface 40 unobstructed for movement of the positioning means 38 therealong. The cam surface 40 opens outwardly away from each end of thecarrier 28. The cam surface 40 is dimensioned to receive therein alifter roller 52 of the positioning means 38.

[0042] For travel between workstations, the carrier 28 is supported in avertically raised condition on the trolley 26 by latch means 54.Referring now to FIGS. 2-4, and more particularly to FIG. 3, the latchmeans 54 can include a latch arm 56 operatively connected to a lever arm58 by a transfer link 60. The latch arm 56 pivots about a fixed pointdefined by a pivot pin 62 extending between parallel plates 48 connectedto the trolley 26 as shown in FIG. 4. A pin-receiving portion 64 of thelatch arm 56 receives therein a pin 66 fixed to the parallel plates 48provided on the carrier 28. The lever arm 58 is pivotally mountedoutside of one of the plates 48 about a fixed pivot point 68. The leverarm 56 is preferably biased, such as by a spring means 70, or the like,towards the position shown in FIG. 3.

[0043] In the embodiment shown in FIGS. 4-5, the lowerator 18 is shownprovided at a workstation 14. The workstation 14 is shown with a base72, and according to this embodiment, the lowerator 18 is fixedlymounted to the base 72 by appropriate support structure 74. Thelowerator 18 can include a lifter arm 76 adapted for rotationalmovement. A roller 78 is rotatably mounted adjacent the terminal freeend of the lifter arm 76. The roller 78 is receivable with respect tothe cam surface 40, such as the illustrated channel. Means 80 foractuating the latch means 54 is provided adjacent the terminal end ofthe lifter arm 76, and extends radially outward from lifter roller 78.The latch actuating means 80 can include an actuator pin 92 projectingto engage the lever arm 58. The lowerator 18 is preferably motor-driven,and a motor 82 and gearbox 84 are provided in operative association withthe lifter arm 76. The motor 82 can be powered by any desiredconventional means. The radial dimensions of lifter arm 76 are suchthat, during rotational movement thereof, roller 78 is received withrespect to the cam surface 40, such as the channel of the carrier 28,when the conveyance means 10 is positioned at the workstation 14.

[0044] Referring now to FIGS. 2 and 5, the lowerator 18 is provided inalignment at opposite ends of the conveyance means 10. The lowerator 18is positioned at an appropriate workstation 14 in relation to the pathof travel of the conveyance means 10 such that, after arrival of theconveyance means 10 at the workstation 14, rotational movement of thelifter arm 76 brings the roller 78 into contact with the cam surface 40,such as the channel of the carrier 28. As best seen in FIG. 5, guidemeans 86 is disposed at the workstation 14 to facilitate properalignment of the lowerator 18 with the conveyance means 10, and prohibitunwanted lateral movement of the conveyance means 10 during operation ofthe lowerator 18. These guide means 86 can include horizontally orientedguide rollers 88 arranged on support posts 90 in opposing fashion oneither side of horizontal member of the carrier 28 to define a paththere between for receiving the conveyance means 10. Two such pairs ofguide means 86 are preferably provided, one pair at predeterminedlocations of each end of the horizontal member when the conveyance means10 come to a stop at the workstation 14.

[0045] Referring now to FIGS. 6A-6C, after arrival of the conveyancemeans 10 at the appropriate workstation 14, rotational movement of thelifter arm 76 commences. In the lowering cycle of operation, the lifterarm 76 rotates forwardly from a start position, shown in FIG. 4,bringing the roller 78 into engagement with the cam surface 40, such asthe illustrated channel of the carrier 28, best seen in FIG. 6A. Withcontinuing rotational movement of the lifter arm 76, the roller 78circumscribes an arcuate path while moving upwardly within theillustrated channel, where the roller 78 engages cam surface 40 to urgethe carrier 28 vertically upwards until reaching the maximum verticalheight of the arc as best seen in FIG. 6B. This action drives the latchpin 66 upwards and out of engagement with the latch arm 56. Simultaneouswith the upwards movement of the carrier 28, actuator pin 92 actuatesthe lever arm 58, urging the lever arm 58 to pivot about an axis in afirst, clockwise direction. The rotation of the lever arm 58 urges thetransfer link 60 in an outward direction “A” away from the pin 66 todraw the latch arm 56 out of the vertically downward path of travel ofthe pin 66. Continued forward rotational movement of the lifter arm 76effects vertically downward movement of the carrier 28 relative to thetrolley 26, until the carrier 28 is brought into position at theworkstation 14 as best seen in FIG. 6C. Locator pins (not shown) may beprovided at the workstation as necessary to receive the workpiece and/orcarrier 28. It will be appreciated that the length of the cam surface40, such as the channel of the carrier 28, is sufficient to provide forunimpeded movement of the roller 78 throughout the range of motion ofthe lifter arm 76, both in the counter clockwise direction, and forraising the carrier 28 to the latched position, the clockwise direction.

[0046] From the foregoing it will be appreciated that the operation ofraising the carrier 28 into latched engagement with the trolley 26 takesplace according to the foregoing description, except in reverse order ofoperation and with the lifter arm 76 rotating clockwise. Additionally,the latch arm 56 is not retracted by actuation of the lever arm 58during the raising operation. As indicated, the lever arm 58 is biasedtowards its default position after the actuator pin 92 moves out ofengagement therewith during the lowering operation. The latch arm 56 isthus positioned in the vertically upward path of travel of the pin 66.The latch arm 56 is provided with a ramped travel surface 94 for the pin66. The ramped surface 94 is angled such that engagement of the latchpin 28 with the ramped surface 94 urges the latch arm 56 to pivotoutward in direction “A” until the latch pin 66 passes out of engagementwith the ramped surface 94, and the spring means 70 urges the latchmeans back to a biased position so that the latch pin 66 can be broughtinto engagement with the pin-receiving portion 64 of the latch arm 56 asthe roller 78 moves through an arcuate path in the clockwise direction.

[0047] Those of skill in the art will appreciate that the harmonicmotion of the carrier 28 brought about by the arcuate rotational path ofthe lifter arm 76 results in a so-called “soft touch” motion of thecarrier 28 proximate the upper and lower limits of vertical range ofmotion. This “soft touch” motion is beneficial in reducing wear and tearon the lowerator 18, as well as providing for the relatively delicatehandling of the workpiece.

[0048] Referring now to FIGS. 7-11, and more particularly FIGS. 7 and 8,the preferred embodiment of a lowerator 18 a according to the presentinvention is illustrated. The present invention discloses an apparatusfor transporting at least one workpiece along at least one rail 20 adefining a path 12 a of travel through a workstation 14 a. While thepresent invention preferably includes a single electric monorailoverhead system, the invention contemplates application to other knownconfigurations of workpiece conveyors including multi-rail, bothelectric and non-electric, or non-electric monorail configurations. Inthe preferred configuration, a trolley 26 a is movable along the rail 20a and is controllable to stop at the workstation 14 a by appropriateswitches and/or sensors and control circuitry as is known to thoseskilled in the art. A carrier 28 a is connected to the trolley 26 a forsupporting at least one workpiece during movement of the trolley 26 aalong the rail 20 a with respect to the workstation 14 a. The carrier 28a is movable between a raised position, illustrated in FIGS. 7 and 8,and a lowered position, shown in phantom in FIG. 7, when positioned atthe workstation 14 a. At least one latch 54 a is provided formaintaining the carrier 28 a in the raised position with respect to thetrolley 26 a when the latch 54 a is in the locked position. The latch 54a allows movement of the carrier 28 a to the lowered position when thelatch 54 a is in the released position. An actuator 16 a is provided foreach latch 54 a. Each actuator 16 a is movable from a first position toa second position. As the actuator moves from the first position to thesecond position, the actuator 16 a engages the carrier 28 a, releasesthe latch 54 a, and lowers the carrier 28 a to the lowered position.While moving in the reverse direction from the second position to thefirst position, the actuator 16 a raises the carrier 28 a, locks thelatch 54 a, and disengages from the carrier 28 a.

[0049] Preferably, the actuator 16 a is supported separate from the rail20 a. In the preferred configuration, the actuator 16 a is supportedfrom the floor or base 72 a of the workstation 14 a. The actuator 16 ahas a cam follower or roller 78 a connected to one end of a rotatablecrank arm 76 a. The cam follower is engageable with a cam surface 40 aformed on the carriage 28 a. The cam follower 78 a is engageable withthe cam surface 40 a when the carriage 28 a is stopped at theworkstation 14 a. Preferably, the cam follower 78 a is in the form of aroller having an inner cylindrical spool surface positioned betweenradially enlarged flange members capable of guiding and maintaining thecarrier 28 a in operative contact with the cam follower 78 a as thecarrier 28 a is moved between the raised position and the loweredposition. In the preferred configuration, the cam surface 40 a is formedas a bottom surface of the carrier 28 a.

[0050] Referring now to FIGS. 7-9C, and more particularly to FIGS.9A-9C, the preferred embodiment of the latch 54 a includes a second camengaging surface 40 b for actuating the latch between the lockedposition and the released position. The latch 54 a is rotated inresponse to engagement of the second cam surface 40 b by the camfollower 78 a as the cam follower 78 a simultaneously moves along thefirst and second cam surfaces 40 a, 40 b. In the illustrated embodiment,the latch 54 a is pivotally connected to the carrier 28 a. A pair oftelescoping posts or vertical elements 34 a connect the carrier 28 a tothe trolley 26 a. Slide blocks or bearing blocks 30 a are enclosedwithin the telescoping posts 34 a to prevent infiltration of foreignmatter, while guiding movement of the carrier 28 a with respect to thetrolley 26 a.

[0051] In the preferred configuration, best seen in FIGS. 9A, 9B and 10,at least one position sensor 96 a, 96 b, and 96 c is supported withrespect to the telescoping post 34 a for generating a signalcorresponding to a retracted and locked position of the post(illustrated in FIG. 10 in solid line). The position sensor 96 a can besupported with respect to the post 34 a to sense the position of thetelescoping portion of the post 34 a relative to the stationary portion35 a, as shown in FIG. 10. Alternatively or additionally, the sensor 96b can be supported with respect to the telescoping portion of the post34 b to sense the position of a surface 67 of the latch 54 b, as shownin FIG. 9A. The sensor 96 b can be mounted to the stationary portion 35b with a bracket 99. Alternatively or additionally, the sensor 96 c canbe supported with respect to the telescoping portion of the post 34 c tosense the position of a tip 69 of the latch 54 c, as shown in Fib. 9B.The sensor 96 c can be mounted to the stationary portion 35 b of thepost 34 c with a bracket 101. The sensors 96 b and 96 c can bepositioned approximately one eighth of an inch (⅛″) away from thesurface 67 and the tip 69, respectively, when the latch 54A is in alocked position. The sensors 96 a, 96 b and 96 c are shown schematicallyin FIGS. 10, 9A and 9B respectively. Control means 98 a, 98 b, and 98 csuch as one or more control circuits, is provided for receiving thesignal from one or more of the position sensors 96 a, 96 b, and 96 c forprocessing signals in accordance with a program stored in memory. Means100 a is provided for sensing if the carriage or workpiece conveyancemeans 10 a is at the workstation 14 a. If the carrier 28 a is at theworkstation 14 a, the control means 98 a (FIGS. 7 and 10) determines ifthe latch 54 a is in the locked position. If the latch 54 a is not inthe locked position, the control means 98 a generates an error signal.If the latch 54 a is in the locked position, the control means 98 aactuates the actuator 16 a in a first direction of travel moving fromthe first or start position to an intermediate position. When theactuator 16 a is in the intermediate position, the control means 98 adetermines if the latch 54 a has been released from the locked position.If the latch 54 a is still in the locked position when the actuator 16 ais in the intermediate position, the control means 98 a generates anerror signal. If the latch 54 a is in the released position when theactuator 16 a is in the intermediate position, the control means 98 acontinues actuation of the actuator 16 a from the intermediate positionto a second position causing the carrier 28 a to move from the raisedposition to the lowered position. After work has been performed on theworkpiece at the workstation 14 a when the carrier 28 a is in thelowered position, the control means 98 a actuates the actuator 16 a in asecond direction of travel to move from the second position to the firstposition. When the actuator 16 a has returned to the first position, thecontrol means 98 a determines if the carrier 28 a is in the raised andlocked position through the position sensor 96 a. If the carrier 28 a isnot in the raised and locked position when the actuator 16 a is in thefirst position, the control means 98 a generates an error signal. If thecarrier 28 a is in the raised and locked position when the actuator 16 ais in the first position, the control means 98 a generates a signal foractivating the motor driven trolley 26 a for moving the carriage 28 afrom the workstation 14 a.

[0052] In operation, conveying means such as trolley 26 a is drivenalong rail means defining a path of travel with respect to a workstation14 a. The conveying means includes a carrier 28 a for supporting atleast one workpiece for delivery to the workstation 14 a. As the trolley26 a and carrier 28 a approach the workstation 14 a, the carrier 28 aoperably engages guide means 86 a for aligning and orienting the carrier28 a in the proper position as the carrier 28 a enters the workstation14 a for operative engagement with the lowerator 18 a located at theworkstation 14 a. The guide means 86 a can include a pair of convergingguide rails to direct the leading edge of the carrier 28 a into theproper position as the carrier 28 a enters the workstation 14 a, and/orcan include a pair of rollers 88 a rotatably supported on posts 90 a forguiding the leading edge of the carrier 28 a into the proper orientationas it enters the workstation 14 a.

[0053] When the trolley 26 a has reached a predetermined position at theworkstation 14 a, the motor driven trolley 26 a is stopped and a signalis generated by a sensor 100 a indicating that the carrier 28 a is atthe workstation. The signal is received by the control means 98 a andprocessed according to a control program stored in memory. The controlprogram can include the steps illustrated in FIG. 11. Initially, theprogram determines if the carrier 28 a is at the workstation in querystep 200. If a signal indicating that the carrier 28 a is at theworkstation 14 a is not received, the program branches back to reiteratethe same query in step 200. When a signal is received from the sensor100 a indicating that the carrier 28 a is at the workstation 14 a, theprogram continues to the next query step 202 to determine if theposition sensor 96 a indicates that the carrier 28 a is in the raisedand locked position. The position sensor 96 a can be in the form of aproximity sensor as illustrated in FIG. 10 positioned appropriately tooperatively indicate the presence of a radially extending metal portionof the post 34 a when in the raised and locked position as illustratedin solid line. If the position sensor 96 a is not generating a signal,the control program branches to generate an error signal in step 204indicating that a sensor failure has occurred. After indicating thatthere is a sensor failure, the program continues to step 206 wherefurther operations are stopped pending operator determination of thecause of the sensor error reported in step 204. If a signal is receivedfrom the position sensor 96 a indicating that the carrier 28 a is in theraised and locked position, the program continues on to step 208 wherethe motor 82 a is activated in order to drive the lifter arm 76 athrough gear box 84 a to bring the cam follower or roller 78 a intooperative engagement with the first cam surface 40 a formed on thebottom of the carrier 28 a. Preferably, the lifter arm 76 a is driven ina first rotational direction and engages the bottom of the carrier 28 aprior to reaching the upper limit of travel through the defined arc ofrotation. As best seen in FIG. 9A, as the lifter arm 76 a continues torotate from the start position, and when at approximately 16° ofrotation, the roller 78 a has lifted the carrier 28 a a sufficientdistance to relieve the weight from the latch 54 a, or approximately0.375 inches. As the roller 78 a is raising the carrier 28 a, the roller78 a simultaneously engages the second cam surface 40 a as the roller 78a continues to engage the first cam surface 40 a. The lifting motion ofthe carrier 28 a raises the latch 54 a a sufficient distance to removethe pin 66 a from the pin-receiving portion 64 a of the latch arm 56. Asthe carrier 28 a is being lifted by the roller 78 a, the outwardlyextending metal portion of the post 34 a is also raised and moved towardthe position shown in phantom in FIG. 10. As the roller 78 a reaches theupper limit of travel, the radially outwardly extending metal portion ofthe post 34 a reaches the position shown in phantom and the signal fromthe position sensor 96 a is lost or discontinued. The uppermost positionof the roller 78 a is shown in FIG. 9B where the roller 78 a hascontinued simultaneous contact with the first and second cam surfaces 40a, 40 b and is in the process of rotating the latch arm 56 a about thepivot 62 a to unlatch the carrier 28 a from the trolley 26 a. When inthis uppermost or intermediate position, the control program proceeds tothe next query step 210 to determine if the position sensor signal hasbeen discontinued. If the signal from the position sensor 96 a is stillpresent, the program branches to step 212 to indicate a sensor and/orrelease error, since the carrier 28 a has not been raised a sufficientdistance to unlatch the carrier 28 a from the trolley 26 a and continuedmovement would therefore cause damage to the conveying structure. Theprogram then continues on to the stop step 206 where no further actionis taken until an operator determines the cause of the error. If thesignal from the position sensor 96 a has been discontinued, the controlprogram continues on to step 214 where rotation of the lever arm 76 acontinues without stopping through the intermediate position to rotatethe actuator to the lowest position placing the carrier 28 a in theposition shown in phantom in FIG. 7. As the roller 78 a passes throughthe intermediate position, the simultaneous engagement with the firstand second cam surfaces 40 a, 40 b rotates the lever arm 56 a asufficient distance to completely release the pin 66 a and bypass thepin as the carrier 28 a is lowered. The position of the roller 78 aillustrated in FIG. 9C is approximately 45° from the start position andthe carrier 28 a has been lowered approximately 0.375 inches down fromthe fully raised position. When the carrier 28 a is in the lowestposition, work is performed on the workpiece or workpieces that havebeen transferred to the workstation 14 a. After completion of the workbeing performed at the workstation 14 a, an appropriate signal is sentto the control means 98 a and the motor 82 a is activated in the reversedirection to move the lifter arm 76 a through the gear box 84 a from thelowest or second position back toward the first or start position. Thepause for work to be performed is illustrated in step 216 of the controlprogram followed by step 218 indicating reverse rotation of the actuatorto the start position. When rotating in the reverse direction, theroller 78 a passes through the reverse order of movement previouslydescribed, first reaching the position illustrated in FIG. 9C, then FIG.9B, followed by FIG. 9A, and finally back to the start positionillustrated in FIGS. 7 and 8. When in the start position, the radiallyoutwardly extending metal portion of the post 34 a has returned to thesolid line position illustrated in FIG. 10, and the control programcontinues to query step 220 to determine if the position sensor 96 a isgenerating a signal to the control means 98 a. If no signal is receivedfrom the position sensor 96 a, the control program branches to step 222where an error signal is generated indicating a sensor or lock error.The program then continues on to the stop step 206 where no furtheraction is taken until the cause of the error is determined by anoperator. If the signal from the position sensor 96 a is received by thecontrol means 98 a, the program branches to the step 224 allowing themotor trolley 26 a to be energized to remove the carrier 28 a from theworkstation 14 a. Preferably, biasing means 102 a is provided for urgingthe lever 56 a toward the unlocked position of rotation with respect topivot pin 62 a. In the preferred configuration, the lower portion of thecarrier 28 a is formed as a box beam having a cutout portion forreceiving the rotatable latch arm 56 a.

[0054] The present invention discloses a simple, efficient, and reliableassembly system including an overhead rail means defining a path oftravel with respect to a workstation, and means for conveying aworkpiece along the rail means. The conveying means according to thepresent invention includes a carrier for supporting at least oneworkpiece for delivery to the workstation, where the carrier is movablyassociated with the conveying means so as to be vertically positionablebetween raised and lowered positions with respect to the conveyingmeans. A lowerator according to the present invention automaticallymoves the carrier between the raised and lowered positions. Latch meansis provided for securing the carrier to the conveying means in theraised position for transport to and from the workstation. At least onelifter defines a path of travel in first and second directions, whereduring movement in the first direction the lifter actuates the latchmeans to uncouple the carrier from the conveying means, for movementinto the lowered position, and where during movement in the seconddirection the lifter lifts the carrier from the lowered position to theraised position and actuates the latch means so as to secure the carrierto the conveying means in the raised position.

[0055] In the preferred configuration, at least two vertically extendingmembers or posts are provided at opposite ends of the carrier, and alatch and position sensor is associated with each post, where theposition sensor can signal if the carrier has been raised and placed inthe locked position prior to transport out of the workstation, and canalso determine if the carrier has been raised sufficiently and unlatchedprior to movement of the carrier into the lowered position. If either ofthe sensors does not generate the appropriate signal, the controlprogram automatically stops further actuation of the loweratormechanism. It is believed that only one sensor is required for each postin order to determine the position of the vertical member and the latch,however multiple sensors could be provided for additional signals to thecontrol means without departing from the spirit and scope of the presentinvention.

[0056] Referring now to FIG. 12, a simplified schematic diagram of theoverall body assembly line 300 is illustrated. Solid lines between boxesrepresent transport of parts between boxes with an overhead transportsystem. Double lines between boxes represent transport of parts with apallet transport system. The bodyside left hand panel assembly line isillustrated as a single box 302 in this simplified schematic drawing.The bodyside right hand assembly line is illustrated as a single box 304in this diagram. Box 306 illustrates the entire underbody assembly lineand tack weld station in this diagram. In the preferred configuration,the bodyside left hand assembly line 302, bodyside right hand assemblyline 304, and underbody assembly line 306 through the tack weldworkstation are part of individual overhead transport systems for eachof the lines illustrated as ovals in the schematic drawing numbered 308,310, and 312 respectively. The first overhead transport system 308delivers parts or components in various stages of assembly along thebodyside left hand assembly line 302 between the various workstations.

[0057] Preferably, the first overhead transport system 308 is a closedloop system passing through the various workstations and passing througha workpiece support for antler exchange workstation, where the workpiecesupport or antlers can be exchanged depending on the body style or modelto be assembled through the assembly line without interruptingproduction. The first overhead transport system 308 can be supplied withsubassemblies from at least one subassembly line 303 having an overheadtransport system 305.

[0058] The overhead transport systems 308, 305 can be independent fromone another or can be integrated into a single overhead transportsystem. The second overhead transport system 310 transports parts orcomponents in assembled or partially assembled states between thevarious workstations of the bodyside right hand assembly line 304.Preferably, the second overhead transport system 310 is a closed loopsystem passing through each of the workstations of the bodyside righthand assembly line 304 and through a workpiece support or antlerexchange workstation. The second overhead transport system 310 can besupplied with subassemblies from at least one subassembly line 307having an overhead transport system 309. The overhead transport systems309, 310 can be independent from one another or can be integrated into asingle overhead transport system. At the workpiece support or antlerexchange workstation, the workpiece support or antlers carried by eachoverhead transport system carriage can be changed as required dependingon the body style or model to be assembled without interruptingproduction.

[0059] The third overhead transport system 312 carries parts orcomponents in assembled or partially assembled condition between thevarious workstations for the underbody assembly line 306 and tack weldstation. Preferably the third overhead transport system 312 is a closedloop system passing through each workstation of the underbody assemblyline 306 including the tack weld station, and through a workpiecesupport or antler exchange workstation. The third overhead transportsystem 312 can be supplied with subassemblies from at least onesubassembly line 311 having an overhead transport system 313. Theoverhead transport systems 312, 313 can be independent from one anotheror can be integrated into a single overhead transport system.

[0060] The overall assembly line can also include a roof assembly line315 having a fourth overhead transport system 317. The fourth overheadtransport system 317 carries parts or components in assembled orpartially assembled condition between the various workstations for theroof assembly line 315. Preferably the fourth overhead transport systemis a closed loop system passing through each workstation of the roofassembly line 315 and through a workpiece support or outer exchangeworkstation. The fourth overhead transport system 317 can be suppliedwith subassemblies from at least one subassembly line 319 having anoverhead transport system 321. The overhead transport systems 317, 321can be independent of one another or can be integrated into a singleoverhead transport system.

[0061] The workpiece support or antler exchange workstation permits theworkpiece support or antlers for each overhead transport carriage to beexchanged depending on the automotive body style or model to be producedthrough the assembly line without interrupting production. In itspreferred form, each overhead transport system, 305, 308, 309, 310, 312,313, 317, 321 has an electric monorail system. In its most preferredconfiguration, each overhead transport system 305, 308, 309, 310, 312,313, 317, 321 is an electric monorail system having a plurality ofcarriages with a plurality of vertically extending supports or postswith lower portions moveable between a lowered position and a raisedposition. The electric monorail system conveys the carriages along apath of travel between workstations on the assembly line to convey aworkpiece to one or more workstations along the path of travel and toraise and lower the workpiece with respect to a tooling fixture,workpiece support, or geometry fixture at the various workstations asrequired. Details of the overhead transport systems 305, 308, 309, 310,312, 313, 317, 321 can be obtained from the description of FIGS. 1-11given in greater detail above.

[0062] Referring now to FIGS. 13-15, by way of example and notlimitation, one possible configuration of the overhead transport system312 of the underbody assembly line and tack weld station 306 isillustrated. The configuration illustrated in FIG. 13 shows an electricmonorail system 320 with an overhead monorail 322 supporting first andsecond carriages 324, 326 for movement along the path of travel.Vertically extending supports or pillars 328 extend downwardly from thefirst and second carriages 324, 326. A horizontal support member 330extends between the vertically extending supports or pillars 328.Preferably, a single drive mechanism 332 is associated with eachvertically extending support or pillar 328 for unlatching the horizontalsupport member 330 from a locked position with respect to the verticallyextended supports or pillars 328 and for lowering the horizontal supportmember 330 to a lowered position causing the carried workpiece to betransferred to a geometry fixture, sometimes referred to herein as atooling fixture or workpiece support, as required for the particularworkstation. The single drive mechanism 332 operates in synchronizationwith the other single drive mechanism associated with the othervertically extending supports or pillars 328 to raise the horizontalsupport member 330 from the lowered position and to re-latch thehorizontal support member 330 with respect to the vertically extendingsupports or pillars 328 prior to the first and second carriages 324, 326leaving the workstation for further movement along the overhead rail322.

[0063] Referring now to FIG. 14, the horizontal support member 330preferably provides the ability to interchange the workpiece support orantler nest 334 to match the particular automotive body style or modelto be produced on the assembly line without interrupting production. Theworkpiece support or antler nest 334 is engageable on locating pins 336located on the horizontal support member 330. The locating pinsaccurately locate the workpiece support or antler nest 334 with respectto the horizontal support member 330. Preferably, the locating pins 336include at least one outwardly driven, or biased, latch member or ballfor locking the nest 334 in position on the support member 330.Vertically extending retainer plates 338, as shown in FIG. 14C, oneither side of the horizontal support member 330 maintain the workpieceor support or antler nest 334 from lateral shifting with respect to thehorizontal support member 330. If required, a latch member can beprovided to lock the workpiece support or antler nest 334 with respectto the horizontal support member 330. The workpiece support or antlernest 334 includes transversely extending surfaces 340 defining at leastone slot or pocket 342 for engagement by an automated workpiece supportor antler nest exchange unit.

[0064] Referring now to FIGS. 14D and 14E, each end of the antler nestor cross bar 334 b can be releasibly connected to couplings 28 b, 28 cwith locks 400 a, 400 b at the lower ends of the telescoping posts 328 ato define the carrier. The locks 400 a, 400 b can include housings 404a, 404 b mounted on the lower ends of each telescoping posts 328 a ofthe carrier. The carrier is formed of three parts connectible to oneanother; namely couplings 28 b and 28 c, and the antler nest or crossbar 334 b bridging the gap between the couplings 28 b and 28 c. Eachhousing 404 a, 404 b can include guide slots 406 a and 406 b forreceiving and guiding the travel of locking pins 408 a and 408 b,respectively, between an extended locking position and a retractedreleasing position. The locking pins 408 a and 408 b are connected torotatable links 410 a and 410 b, respectively. The links 410 a and 410 bare pivotally coupled together by a common pivot pin 412. A reciprocalactuator pin 414 operably engages links 410 a and 410 b adjacent thecommon pivot pin 412. The reciprocal actuator pin 414 is biased in afirst position by a biasing means 413, such as a spring, positionedbetween a washer 418 engageable with the frame 404 and a flange 420extending from the pin 414 adjacent one end. The biased position of thepin 414 corresponds to the extended, locked position of the locking pins408 a and 408 b relative to the couplings 28 b, 28 c and the antler nest334 b. The locking pins 408 a and 408 b operably engage with the guideslots 406 a and 406 b and are engageable with the slots 422 a and 422 bformed in corresponding brackets 424 a, 424 b mounted on opposite endsof the antler nest 334 b.

[0065] In operation, each end of an antler nest 334 b is engaged with acorresponding coupling 28 b, 28 c by moving the reciprocal actuator pin414 against the urging biasing of means 413 to a second position bydrive means 426. The drive means 426 can be an electric, hydraulic orpneumatic linear actuator for moving the actuator pin between the firstand second positions. As the actuator pin 414 travels from the firstposition, or locked position, to the second position, or releasedposition, the common pivot pin 412 is moved to rotate links 410 a and410 b. Contemporaneously, the locking pins 408 a and 408 b travel in theguide slots 406 a and 406 b towards each other. When the pin 414 is inthe second position, corresponding to an unlocked position between theantler nest 334 b and the couplings 28 b, 28 c, the antler nests 334 bcan be removed and exchanged by lifting movement to slide locking pins408 a and 408 b out from engagement with the brackets 424 a and 424 bthrough corresponding slots 422 a and 422 b. A new antler nest 334 b canbe replaced by directing corresponding brackets 424 a and 424 b over thelocking pins 408 a and 408 b when lowering the antler nest 334 b withrespect to the couplings 28 b, 28 c of the carrier. After the antlernest 334 b has been lowered and the locking pins 408 a and 408 b arepositioned in the slots 422 a and 422 b, the actuator pin 414 can bemoved to the first position by deactivating the drive means 426 allowingthe biasing means 413 to move the actuator pin 414 from the secondposition to the first position. As the drive means 424 moves theactuator pin 414 to the first position, the links 410 a and 410 b rotatetoward a vertically aligned position and locking pins 408 a and 408 bmove away from one another toward the ends 426 a and 426 b of the slots422 a and 422 b to lock the brackets 424 a, 424 b of the antler nest 334b to the couplings 28 b, 28 c to define the new carrier configuration.It should be recognized that the operation of the drive means could bereversed to move the actuator pin downwardly to release and upwardly tolock without departing from the scope of the present invention.Furthermore, it should be recognized that the operation of the lockingpins could be reversed to move toward one another to lock and away fromone another to release without departing from the scope of the presentinvention. The present invention provides means for coupling eachtelescoping post to a selected interchangeable antler nest. Means isprovided for releasibly locking each telescoping post with respect tothe selected one of a plurality of interchangeable antler nests, wherethe releasible locking means is moveable between a released position anda locked position. Drive means is provided for moving the locking meansbetween the released position and the locked position. Biasing meansurges the locking means toward the locked position in a normal state.

[0066] Referring now to FIGS. 15 and 16, a workpiece support or antlernest exchange workstation is provided along the path of travel of theoverhead transport system. At the exchange workstation 344, storagefacilities are provided for holding a sufficient quantity of workstationsupports or antler nests 334 to exchange out a predetermined portion, oran entire assembly line of the electric monorail system 320. As bestseen in FIG. 16, storage locations 346 can be provided for a pluralityof workpiece supports or antler nests 334 extending vertically andhorizontally along the path of travel of the overhead transport system.Storage locations 346 can be provided for the workpiece support orantler nest 334 being taken out of service, while a new workpiecesupport or antler nest 334 is taken from a storage location 346 to beput into service. One or more automated handling units 348 can beprovided for engaging members with respect to the one or more slots orpockets 342 formed in the workpiece support or antler nest 334 currentlyengaged on the horizontal support member 330. Alternatively, as shown inFIG. 16A, a robot 430 can engage an antler nest 334 c, mounted oncouplings 28 d, 28 e with locks 400 d and 400 e, by lifting the antlernest 334 c with an appropriately shaped gripper assembly. Clamps 431 a,431 b can be provided on the gripper assembly for grasping the antlernest during the exchange and transport process. If required, thecorresponding latch or latches are disengaged to release the workpiecesupport or antler nest 334 from the horizontal support member 330. Theautomated handling unit 348 then lifts the workpiece support or antlernest 334 from the locating pins 336 to disengage the workpiece supportor antler nest 334 from the horizontal support member 330. After theworkpiece support or antler nest 334 is disengaged from the horizontalsupport member 330, the workpiece support or antler nest 334 can bepositioned in an empty storage location 346. Depending on the speed ofthe overhead transport system, the same automated handling unit, or adifferent automated handling unit, at the same exchange workstation, orat a second exchange workstation, can locate and retrieve the desirednew workpiece support or antler nest 334 from the corresponding storagelocation 346. The automated handling unit 348 removes the workpiecesupport or antler nest 334 from the storage location 346 and positionsthe workpiece support or antler nest 334 directly above the locatingpins 336 on the horizontal support member 330. The automated handlingunit 348 lowers the new workpiece support or antler nest 334 onto thelocating pins 336 to position the workpiece support or antler nest 334with respect to the horizontal support member 330. If required, a latchor multiple latches are actuated to lock the workpiece support or antlernest 334 with respect to the horizontal support member 330. The overheadtransport system then can move the trolley or workpiece carrier 350 fromthe exchange loading station to the next station along the path oftravel of the overhead rail 322. The process is then repeated for eachsuccessive trolley 350 delivered to the exchange workstation as requiredfor a portion of or the complete number of trolleys existing in theoverhead transport system as required for the particular automotive bodystyle or model to be assembled.

[0067] Referring now to FIG. 16A, an exchange workstation 344 a isprovided to exchange an antler nest 334 b. Storage facilities can beprovided at the exchange workstation 344 a for holding a sufficientquantity of antler nests 334 b, of the same or different configurationsas required, to exchange out a predetermined portion, or an entireassembly line of the electric monorail system 320. Storage locationssimilar to storage locations 346 can be provided for each antler nest334 b extending vertically and horizontally along the path of travel ofthe overhead transport system. Empty storage locations can be providedfor storing a workpiece support or antler nest 334 b being taken out ofservice, while a replacement workpiece support or antler nest 334 b istaken from another storage location and put into service. The exchangeworkstation 344 a can exchange antler nests 334 b having locks 400. Theexchange workstation 344 a can have a plurality of drive means 426 forreleasing each lock engaging the antler nest 334 b with the telescopingposts 328 a through couplings 28 c and 28 b. FIGS. 14D and 14E provide adetailed illustration of this engagement. The exchange workstation 344 acan include one or more automated exchange units 430 for lifting anantler nest 344 b away from the telescoping posts 328 a of the carrier.The unit 430 can include jaws 431 a and 431 b to grasp the antler nest334 b and disengage the antler nest 334 b from the coupling 28 c and 28b of the carrier.

[0068] Referring now to FIG. 17, the trolley or workpiece carrier 350can stop at one or more manual or automated loading stations 352. Theloading station 352 can be located before the first flexible bodyassembly workstation, or in between flexible body assembly workstationsas required. At the manual loading station 352 as illustrated in FIG.17, parts can be supplied in quantity for manual placement with respectto the workpiece support or antler nest 334 carried by the trolley 350.Referring now to FIG. 18, an automated loading/unloading station 354 isillustrated. The overhead electric monorail system 320 delivers thetrolley 350 to the workstation. If required, the horizontal supportmember 330 is lowered by single drive mechanisms 332 (FIG. 13) fortransferring the supported workpiece or component to a stationaryworkpiece support or geometry fixture (not shown) at the workstation.Automated equipment, such as one or more robots 356, can be used totransfer parts to and from the overhead electric monorail system 320with respect to a second part or component delivery system 358. Aplurality of predefined fixtures 360 can be provided for each robot 356or automated loading and unloading equipment in order to properly engageand hold the current workpiece corresponding to a particular automotivebody style or model for transfer from one transport system to the other.This action can be performed to load the overhead monorail system 320,or to unload the overhead monorail system 320. The predefined fixtures360 can be changed as required for meeting the production requirementsof the particular automobile bodystyle or models to be manufacturedthrough the assembly line.

[0069] Referring now to FIGS. 19-20, a flexible body assemblyworkstation is illustrated in detail. This workstation can be one of aplurality along a single overhead transport system 308, 310, 312, forassembly of the left hand bodyside, right hand bodyside or underbodyassembly lines 302, 304, 306 respectively. Various modifications can bemade to the flexible body assembly workstation without departing fromthe disclosure of the present invention. By way of example and notlimitation, the number, type, and location of the automated robots canbe changed and modified as required for the particular workstationdepending on the work to be performed. By way of example and notlimitation, the flexible body assembly workstation can perform thefunction of a geometry workstation, a respot workstation, a loading orunloading station, a sealer station, a stud welding workstation, a MIGwelding workstation, and a product inspection workstation. The flexiblebody assembly workstation 362 preferably includes one or more robots 364positioned on either an overhead gantry or platform and/or at floorlevel, as required for the particular function to be performed at theworkstation 362. The flexible body assembly workstation 362 alsoincludes an overhead electric monorail system 320 extending through theworkstation for delivering parts, or partially assembled components forfurther assembly at the workstation. As previously described, theelectric monorail system 320 includes an overhead rail 322 supporting atrolley or workpiece carrier 350 by first and second carriages 324, 326connected to the overhead rail 322. Vertically extending supports orpillars 328 extend downwardly from each carriage 324, 326 to support ahorizontal support member 330 there between. A workpiece support orantler nest 334 is operably engaged with the horizontal support member330. A single drive mechanism 332 is provided for each verticallyextending support or pillar 328 to engage and unlock the horizontalsupport member 330 from the vertically extending supports or pillars 328prior to being lowered into a lowered position to transfer the workpieceor component from the antler nest 334 to a geometry fixture, sometimesreferred to herein as a tooling fixture or workpiece support, located atthe flexible body assembly workstation 362. The flexible body assemblyworkstation 362 includes workpiece support or geometry fixturescorresponding to the number of different automotive body styles and/ormodels to be produced through the assembly line. Workpiece supports orgeometry fixtures 366 a, 366 b, 366 c, 366 d are illustrated tocorrespond to each of four automotive body styles and/or modelsrespectively to be built through the flexible body assembly workstation362. The workpiece support or geometry fixtures can be moved relative tothe flexible body assembly workstation 362 in order to bring theappropriate workpiece support or geometry fixture into position toreceive the carried workpiece or a component from the trolley 350.Providing a single geometry fixture at each workstation for theparticular body style or model to be assembled eliminates variationbetween the geometry of successively assembled parts passing through theworkstation, as is commonly experienced with systems based on a palletdelivery configuration. Consistency between the component parts isdesirable to achieve the quality standards and tolerances required byautomotive manufacturers. Since each workpiece or component is placedinto the same geometry fixture corresponding to the same body style ormodel to be assembled, consistent part production and improved tolerancespecifications can be met with the present invention. As the horizontalsupport member 330 of the trolley 350 is lowered into the lowerposition, the supported workpiece or component is transferred from theworkpiece support or antler nest 334 to the corresponding geometryfixture, such as 366 a, corresponding to the style or model to beassembled. The workpiece support geometry fixtures 366 a, 366 b, 366 c,366 d, are moveable along a predetermined path to change the geometryfixtures as required for the product mix being assembled through theworkstation 362. By way of example and not limitation, the geometryfixtures can be supported on a roller conveyor for movement along apredetermined horizontal path to locate any one of the geometry fixturesin the operable position or ready position below the overhead rail 322for receiving the next delivered workpiece or component by the trolley350 entering the flexible body assembly workstation 362. The geometryfixture handling system 368, such as roller conveyor 370 can exchangethe furthest apart geometry fixtures, by way of example and notlimitation 366 a and 366 d with each other within the cycle timepermitted for the removal of a finished workpiece or component from theworkstation 362 and the delivery of the next workpiece or component tothe flexible body assembly workstation 362.

[0070] An alternative geometry fixture handling system 368 isillustrated in FIGS. 21, 22 and 23. An “H-Gate” configuration isillustrated in FIGS. 21-23. In this configuration, a rail shuttle system372 is provided passing through the center line of the flexible bodyworkstation 362 in order to move a geometry fixture 366 a from theoperable position or ready position to a standby position 374 on eitherside of the operable position 376 along the rails 378. On either side ofthe workstation 362, transversely extending fixture delivery systems 380extend on either side of the rails 378. This configuration gives thefixture delivery handling system 368 its distinctive “H” moniker. Thefixture delivery conveyors 380 can include one or more geometry fixtures366 a, 366 b, 366 c for delivery to the operable position 376. TheH-Gate system delivers a new geometry fixture 366 a to the standbyposition 374. After work has been completed on the workpiece at theflexible body assembly workstation 362 in the operable position 376, andthe workpiece has been lifted from the geometry fixture 366 b, theshuttles 382, 384 are reciprocated along the rails 378 to move thepreviously used geometry fixture 366 b from the operable position 376 toa standby position 374, while the geometry fixture 366 a is moved fromthe standby position on the opposite side of the workstation 362 to theoperable position 376. The previously used geometry fixture 366 b canthen be removed from the shuttle while at the standby position 374. Asillustrated in FIG. 22, the overhead transport system 320 can deliverthe workpiece or a component to the geometry fixture located at theoperable position 376, while the next to be used geometry fixture ispositioned at the standby position 374. When required, the shuttles canbe reciprocated along the rails 378 to move the previously used geometryfixture from the operable position 376 while being replaced with the newgeometry fixture from the standby position 374.

[0071] Referring now to FIG. 23, the overhead transport system isillustrated for lowering a part or component onto the geometry fixturewaiting at the operable position 376. One or more automated robots 356are provided for performing assembly work on the part or componentdelivered to the operable position 376. The fixture delivery conveyors380 can be seen for moving the geometry fixtures to and from the standbyposition on either side of the flexible body assembly workstation 362.

[0072] Referring now to FIGS. 24A-24D, alternative configurations forthe H-Gate geometry fixture delivery system are provided illustrating asingle geometry fixture configuration 386 in FIG. 24A, a dual geometryfixture handling system or H-Gate 388 in FIG. 24B, a triple geometryfixture handling system or H-Gate 390 in FIG. 24C, and a quadruplegeometry handling system or H-Gate 392 in FIG. 24D. This configurationis extremely flexible for providing flexible body assembly workstationscapable of handling single automotive body styles or models, dualautomotive body styles or models, three different automotive body stylesor models, and up to four different automotive body styles or models.

[0073] Using either geometry fixture handling system 368, the flexiblebody assembly workstation 362 according to the present inventionprovides a single geometry fixture for each automotive body style ormodel to be manufactured through the workstation. This increases thereliability, repeatability, and manufacturing tolerances capable ofbeing achieved through the flexible body assembly workstation 362. Theflexible body assembly workstation 362 also increases manufacturingefficiency, by allowing a product mix to be handled through the assemblyline without down time for retooling.

[0074] Referring now to FIG. 25, the present invention includes thetransfer of the underbody assembly from the overhead transfer system 312to a palletized system 394, such as that shown in FIG. 25. Thepalletized system provides a pallet that receives the workpiece orcomponents to be assembled and the pallet remains with the workpieces asthe workpiece travels along the rail system through the underbody respotworkstation, framing workstation, framing respot workstation, closureworkstation, and painting workstation. The underbody respot workstationcan include a plurality of robots 398 for welding areas inaccessibleduring the tacking at the underbody tack workstation. Additional detailsregarding the framing workstations can be obtained from InternationalPublication Number WO 99/24215 published on May 20, 1999 which isincorporated by reference herein.

[0075] While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiments but, on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims, which scope is to be accorded the broadestinterpretation so as to encompass all such modifications and equivalentstructures as is permitted under the law.

What is claimed is:
 1. An apparatus for assembling different automotive body styles on a single assembly line comprising: means for transporting automotive components along a predetermined path for delivery through at least one workstation, each of the components corresponding to one of a plurality of different automotive body styles to be processed on the assembly line; means for selectively positioning one of a plurality of geometry fixtures at a ready position of the at least one workstation to receive the automotive component from the transport system, each of the plurality of geometry fixtures corresponding to a different body style of the plurality of automotive components to be transported along the path; and means for transferring the automotive component between the geometry fixture at the ready position and the transporting means.
 2. The apparatus of claim 1 further comprising: position control means for moving a selected geometry fixture to the ready position within a time period cycle corresponding to moving a first component out of the at least one workstation and delivering a second component to the at least one workstation while different automotive body styles are being assembled in sequence concurrently on the assembly line.
 3. The apparatus of claim 2 wherein the position control means further comprises: means for generating a configuration signal corresponding to an automotive component to be delivered to the at least one workstation next; and drive means, responsive to the configuration signal based on a control program stored in memory, for moving a geometry fixture corresponding to the particular automotive body style to be delivered to the at least one workstation next to the ready position.
 4. The apparatus of claim 1 further comprising: means for stopping the transporting when the transporting means reaches the workstation.
 5. The apparatus of claim 1 further comprising: means for guiding the transporting means into the at least one workstation to align the transporting means with respect to the geometry fixture at the ready position.
 6. The apparatus of claim 1 further comprising: means for preventing the transporting means from moving with respect to the at least one workstation if movement of the transferring means has failed to transfer the automotive component from the geometry fixture to the transporting means.
 7. The apparatus of claim 6 wherein the preventing means further comprises: at least one sensor mounted to the transporting means for generating a vertical position signal corresponding to a vertical position of the transferring means with respect to the transporting means; and drive means, responsive to the vertical position signal from the sensor based on a control program stored in memory, for controlling movement of the transporting means.
 8. The apparatus of claim 1 wherein the transporting means further comprises: a trolley movable along the path; and a carriage movable between a raised position and a lowered position relative to the trolley.
 9. The apparatus of claim 8 wherein the transferring means further comprises: a lowerator having a rotatable crank arm with a roller disposed adjacent an outer end of the crank arm, the crank arm rotatable from a first angular position through a second angular position to a third angular position, such that as the crank arm rotates from the first position to the second position the roller engages the carriage, releases a latch maintaining the carriage in the raised position, and as the crank rotates from the second position to the third position lowers the carriage to transfer the automotive component to the geometry fixture at the ready position when the carriage is in the lowered position.
 10. The apparatus of claim 9 further comprising: lowerator drive means for rotating the crank from the first position to the third position when the carriage is at the ready position, and to rotate the crank arm from the third position to the first position in response to a signal indicating that a processing operation has been completed at the workstation.
 11. The apparatus of claim 10 wherein the lowerator drive means further comprises: a sensor operable to emit a trolley-present signal when the trolley reaches the workstation above the geometry fixture in the ready position; and means for operating the lowerator in response to the trolley-present signal based on a control program stored in memory.
 12. The apparatus of claim 11 wherein the lowerator drive means further comprises: a sensor to emit a carriage-lock signal and a carriage-unlock signal; and control means, responsive to the carriage-lock signal and the carriage-unlock signal based on a control program stored in memory, for rotating the crank arm from the first position to the second position if the carriage-lock signal is initially present, and to continue rotating the crank arm from the second position to the third position if the carriage-lock signal changes to the carriage-unlock signal.
 13. The apparatus according to claim 1 further comprising: at least one robot at the workstation for performing an processing operation on an automotive component delivered to the geometry fixture at the ready position of the workstation.
 14. A method of assembling different automotive body styles on a single assembly line comprising the steps of: transporting automotive components along a predetermined path through at least one workstation with transporting means, each of the components corresponding to one of a plurality of different automotive body styles to be processed on the assembly line; selectively positioning with positioning means one of a plurality of geometry fixtures at a ready position of the at least one workstation to receive the automotive component from the transporting means, each of the plurality of geometry fixtures corresponding to a different body style of the plurality of automotive components to be transported along the path; and transferring the automotive component between the geometry fixture and the transporting means with transferring means.
 15. The method of claim 14 further comprising the step of: controlling the positioning means to move a selected geometry fixture to the ready position within a time period cycle defined between a first component being transported away from the workstation and a second component arriving at the workstation while different automotive body styles are being assembled in sequence concurrently on the assembly line.
 16. The method of claim 15 wherein the controlling step further comprises the steps of: receiving a configuration signal corresponding to the automotive body style to be delivered to the workstation next with electronic control means; and controlling the positioning means to move a geometry fixture to the ready position corresponding to the automotive body style to be delivered next to the workstation based on the configuration signal with the electronic control means and a control program stored in memory.
 17. The method of claim 14 further comprising the step of: controlling the transporting means to prevent the transporting means from moving with respect to the workstation if movement of the transferring means has failed to transfer the automotive component from the geometry fixture to the transporting means.
 18. The method of claim 17 wherein the step of controlling the transporting means further comprises the step of: receiving a vertical position signal corresponding to the vertical position of the transferring means relative to the transporting means with the electronic control means; and controlling the transporting means to stop with the electronic control means if the transferring means has failed to transfer the automotive component from the geometry fixture to the transporting means based on the vertical position signal in accordance with a control program stored in memory.
 19. The method of claim 14 further comprising the step of: controlling the transferring step to prevent transfer of the automotive component from the transporting means to the geometry fixture until the geometry fixture is located at the ready position.
 20. The method of claim 14 where in the step of controlling the transferring step further comprises the step of: receiving a transporting-means-present signal corresponding to the transporting means being positioned at the workstation above the geometry fixture positioned at the ready position with the electronic control means; receiving a fixture-present signal corresponding to the geometry fixture positioned at the ready position with the electronic control means; and controlling the transferring means with the electronic control means based on the transporting-means-present signal, the fixture-present signal in accordance with a control program stored in memory.
 21. The method of claim 14 further comprising the step of: controlling the transferring step in response to a signal indicating if the transferring means is locked in a raised position relative to the transporting means.
 22. The method of claim 21 wherein the controlling step further comprises the steps of: receiving the signal indicating the transferring means is locked in the raised position with electronic control means; engaging the transferring means to rotate a crank arm from a first position to an intermediate position with the electronic control means; determining if the signal is interrupted when the crank arm is rotated to the intermediate position with the electronic control means; continuing engagement of the transferring means to rotate the crank arm from the intermediate position to a second position with the electronic control means if the signal has been interrupted when the crank arm is rotated to the intermediate position from the first position with the electronic control means; receiving a signal corresponding to a completion of work at the workstation with the electronic control means; engaging of the transferring means to rotate the crank arm from the second position to the first position with the electronic control means; and determining if the signal is receivable after the crank has been rotated from the second position to the first position with the electronic control means.
 23. In an automotive assembly line for assembling a plurality of automotive body styles on a single assembly line having a system for transporting automotive body components through at least one workstation, the improvement comprising: means, responsive to at least one signal, for selectively positioning one of a plurality of geometry fixtures corresponding to a particular automotive body style to be assembled in a ready position at the workstation as a plurality of automotive body styles are being assembled on the assembly line in any concurrent sequential order, while a rate of production of the assembly line is maintained. 